sm03a

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SPECIFICATIONS 3.1

NOTEService wear limits are given as a guideline for measuringcomponents that are not new. For measurement specifica-tions not given under SERVICE WEAR LIMITS, see NEWCOMPONENTS.

GENERAL

Type Single cylinder, air cooled, four-stroke

Horsepower @RPM 30 @ 6500

Torque ft-lbs @ RPM 27 @ 3200

Compression Ratio 9.2: 1

Bore 3.50 in. 88.8 mm

Stroke 3.125 in. 79.375 mm

Engine Displacement 30 cu. in. 492 cc

Oil Capacity (with filterchange)

2.0 quarts 1.89 liters

ENGINE IGNITION SPECIFICATIONS

Timing Advance (dur-ing engine cranking)

11° BTDC

Timing Advance (at1200 RPM)

20° BTDC

Regular Idle 1200 RPM

Fast Idle 2000 RPM

VALVE NEW COMPONENTS SERVICE WEAR LIMITS

Fit inguide

Exhaust 0.0015-0.0033 in. 0.0381-0.0838 mm 0.0040 in. 0.1016 mm

Intake 0.0008-0.0026 in. 0.0200-0.0700 mm 0.0035 in. 0.0889 mm

Seat width 0.040-0.062 in. 1.016-1.575 mm 0.090 in. 2.286 mm

Stem protrusion fromcylinder valve pocket

1.975-2.011 in. 50.165-51.079 mm 2.031 in. 51.587 mm

OUTER VALVE SPRING NEW COMPONENTS SERVICE WEAR LIMITS

Free length 2.105-2.177 in. 53.467-55.296 mm 2.105 in. (min) 53.467 mm (min)

Intake 1.751-1.848 in. (closed)

72-92 lbs 33-42 kg

1.286-1.383 in. (open)

183-207 lbs 83-94 kg

Exhaust 1.751-1.848 in. (closed)

72-92 lbs 33-42 kg

1.332-1.429 in. (open)

171-195 lbs 78-88 kg

INNER VALVE SPRING NEW COMPONENTS SERVICE WEAR LIMITS

Free length 1.926-1.996 in. 48.920-50.698 mm 1.926 in. (min) 48.920 mm (min)

Intake 1.577-1.683 in.(closed)

38-49 lbs 17-22 kg

1.112-1.218 in.(open)

98-112 lbs 44-51 kg

Exhaust 1.577-1.683 in.(closed)

38-49 lbs 17-22 kg

1.158-1.264 in.(open)

91-106 lbs 41-48 kg

2002 Buell P3: Engine 3-1

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ROCKER ARM NEW COMPONENTS SERVICE WEAR LIMITS

Shaft fit in bushing (loose) 0.0005-0.0020 in. 0.0127-0.0508 mm 0.0035 in. 0.0889 mm

End clearance 0.003-0.013 in. 0.076-0.330 mm 0.025 in 0.635 mm

Bushing fit in rocker arm (tight) 0.004-0.002 in. 0.102-0.0559 mm

Rocker arm shaft fit in rocker cover (loose)

0.0007-0.0022 in. 0.018-0.056 mm 0.0035 in. 0.0889 mm

PISTON NEW COMPONENTS SERVICE WEAR LIMITS

Compression ring gap (top and 2nd)

0.007-0.020 in. 0.178-0.508 mm 0.032 in. 0.813 mm

Oil control ring rail gap 0.009-0.052 in. 0.229-1.321 mm 0.065 in 1.651 mm

Compressionring sideclearance

Top 0.0020-0.0045 in. 0.0508-0.1143 mm 0.0065 in. 0.1651 mm

2nd 0.0016-0.0041 in. 0.0406-0.1041 mm 0.0065 in. 0.1651 mm

Oil control ring side clearance 0.0016-0.0076 in. 0.0406-0.1930 mm 0.0094 in. 0.2388 mm

Pin fit (loose, at room temperature)

0.00005-0.00045 in.0.00127-0.01143

mm0.00100 in. 0.02540 mm

CYLINDER HEAD NEW COMPONENTS SERVICE WEAR LIMITS

Valve guide in head (tight) 0.0033-0.0020 in. 0.0838-0.0508 mm

Valve seat in head (tight) 0.0035-0.0010 in. 0.0889-0.0254 mm

Head gasket surface (flatness) 0.006 in. total 0.152 mm total 0.006 in. total 0.152 mm total

CYLINDER NEW COMPONENTS SERVICE WEAR LIMITS

Taper 0.002 in. 0.051 mm

Out of round 0.003 in. 0.076 mm

Warpage (gasket surfaces)

Top 0.006 in. 0.152 mm

Base 0.008 in. 0.203 mm

Bore diameter± 0.0002 in.

OS=over size

Standard 3.4978 in. 88.8441 mm 3.5008 in. 88.9203 mm

0.005 OS 3.502 in. 88.951 mm 3.5050 in. 89.0270 mm

0.010 OS 3.507 in. 89.078 mm 3.5100 in. 89.1540 mm

0.020 OS 3.517 in. 89.332 mm 3.5200 in. 89.4080 mm

0.030 OS 3.527 in. 89.586 mm 3.5300 in. 89.6620 mm

CONNECTING ROD NEW COMPONENTS SERVICE WEAR LIMITS

Piston pin fit (loose)0.00125-0.00175 in.

0.03175-0.04445 mm

0.00200 in. 0.05080 mm

Side play between flywheels 0.005-0.025 in. 0.127-0.635 mm 0.030 in. 0.762 mm

Fit on crankpin (loose) 0.0004-0.0017 in. 0.0102-0.0432 mm 0.0027 in. 0.0686 mm

Connecting rod race ID1.6245-1.6250 in.

41.2623-41.2750 mm

1.6270 in. 41.3258 mm

3-2 2002 Buell P3: Engine

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HYDRAULIC LIFTER NEW COMPONENTS SERVICE WEAR LIMITS

Fit in guide 0.0008-0.0020 in. 0.0203-0.0508 mm 0.0030 in. 0.0762 mm

Roller fit 0.0006-0.0010 in. 0.0152-0.0254 mm 0.0015 in. 0.0381 mm

Roller end clearance 0.008-0.022 in. 0.203-0.559 mm 0.026 in. 0.660 mm

OIL PUMP NEW COMPONENTS SERVICE WEAR LIMITS

Oilpressure

1000 RPM 7-12 PSI 48-83 KPa

2500 RPM 10-17 PSI 69-117 KPa

Shaft to pump clearance 0.0025 in. 0.0635 mm

Feed/scavenge inner/outergerotor clearance

0.003 in. 0.076 mm 0.004 in. 0.102 mm

GEARCASE NEW COMPONENTS SERVICE WEAR LIMITS

Cam gear shaft in bushing (loose)

0.0007-0.0022 in. 0.0178-0.0559 mm 0.003 in. 0.076 mm

Cam gear shaft end play(min)

0.005-0.024 in. 0.127-0.610 mm 0.025 in. 0.635 mm

Intake cam gear shaft endplay (min)

0.006-0.024 in. 0.152-0.610 mm 0.040 in. 1.016 mm

FLYWHEEL NEW COMPONENTS SERVICE WEAR LIMITS

Runout Flywheels at rim

0.000-0.010 in. 0.000-0.254 mm 0.010 in. 0.254 mm

Shaft at flywheel end

0.000-0.002 in. 0.000-0.051 mm 0.002 in. 0.051 mm

End play 0.001-0.005 in. 0.025-0.127 mm 0.005 in. 0.127 mm

SPROCKET SHAFTBEARING

NEW COMPONENTS SERVICE WEAR LIMITS

Outer race fit in crankcase (tight)

0.0004-0.0024 in. 0.0102-0.0610 mm

Bearing inner race fit on shaft (tight)

0.0002-0.0015 in. 0.0051-0.0381 mm

PINION SHAFT BEARINGS NEW COMPONENTS SERVICE WEAR LIMITS

Pinion shaft journal diameter1.2496-1.2500 in.

31.7398-31.7500 mm

1.2496 in. (min) 31.7398 mm (min)

Outer race diameter in right crankcase

1.5646-1.5652 in.39.7408-39.7561

mm1.5672 in. (max) 39.8069 mm (max)

Bearing running clearance0.00012-0.00088 in.

0.00305-0.02235 mm

Fit in cover bushing(loose)

0.0023-0.0043 in. 0.0584-0.1092 mm 0.0050 in. 0.1270 mm


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TORQUE VALUES

ITEM TORQUE NOTES

Anti-rotation screws (lifter) 55-65 in-lbs 6-7 Nm Page 3-54

Crankcase 5/16 in. screws 15-19 ft-lbs 20-26 Nm Page 3-75

Crankcase, 3/8 in. screw 22-27 ft-lbs 30-37 Nm Page 3-75

Cylinder head screws See NOTES See NOTES Special pattern to tighten, Page 3-33

Cylinder studs 10-20 ft-lbs 14-27 Nm Special method to tighten, Page 3-75

Flywheel - sprocket nut (for measuring fly-wheel end play)

190-210 ft-lbs 258-285 Nm Page 3-64

Frame to rear isolator fastener 30-33 ft-lbs 41-45 NmLOCTITE® thread locker 262 (red), Page 3-17

Front isolator mounting bolt 63-70 ft-lbs 86-95 NmLOCTITE® thread locker 262 (red), Page 3-22

Front tie bar 30-33 ft-lbs 41-45 NmLOCTITE® thread locker 262 (red), Page 3-21

Gearcase cover screws 80-110 in-lbs 9-12 Nm Special pattern to tighten, page 3-63

Master cylinder mounting screws 4-6 ft-lbs 5-8 NmLOCTITE® thread locker 243 (blue), Page 3-19

Oil filter adapter 8-12 ft-lbs 11-16 NmLOCTITE® thread locker 243 (blue), Page 3-52

Oil pressure signal light switch 50-70 in-lbs 6-8 Nm Page 3-52

Oil pump cover screws 70-80 in-lbs 8-9 Nm TORX, page 3-51

Oil pump mounting screws 125-150 in-lbs 14-17 Nm Page 3-51

Pinion shaft nut 19-21 ft-lbs 26-29 Nm Page 3-62

Pushrod cover screw 30-40 in-lbs 3-5 Nm Page 3-54

Rear engine isolator engine to crankcase 23-27 ft-lbs 31-37 NmLOCTITE® thread locker 243 (blue), Page 3-16

Rocker box cover screws 10-13 ft-lbs 13.6-17.6 Nm Page 3-34

Rocker box to head bolts 11-13 ft-lbs 15-18 Nm Different sizes, Page 3-34

Rocker box to head bolts 135-155 in-lbs 15-18 Nm Different sizes, Page 3-34

Rocker box to head bolts 18-22 ft-lbs 24-30 Nm Different sizes, Page 3-34

Side stand bracket 38-41 ft-lbs 51-55 NmLOCTITE® thread locker 262 (red), Page 3-15

Swing arm pinch bolt 17-19 ft-lbs 23-26 NmLOCTITE® thread locker 243 (blue), Page 3-15

Swing arm pivot shaft 24-26 ft-lbs 32-35 Nm Page 3-15

Top rear tie bar 30-33 ft-lbs 41-45 NmLOCTITE® thread locker 262 (red), Page 3-21

Upper front tie bar 30-33 ft-lbs 41-45 NmLOCTITE® thread locker 262 (red), Page 3-21


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ENGINE 3.2

FUEL

Gasoline/alcohol Blends

The Buell Blast P3 motorcycle has been designed to obtainthe best performance and efficiency using unleaded gasoline(87 pump octane or higher). Some fuel suppliers sell gaso-line/alcohol blends as a fuel. The type and amount of alcoholadded to the fuel is important.

● DO NOT USE GASOLINES CONTAINING METHANOL.Using gasoline/methanol blends will result in starting anddriveability deterioration and damage to critical fuel sys-tem components.

● Gasolines containing ETHANOL: Gasoline/ethanolblends are mixture of 10% ethanol (Grain alcohol) and90% unleaded gasoline. Gasoline/ethanol blends can beused in your motorcycle if the ethanol content does notexceed 10%.

● Gasolines containing ETHER: Gasoline/ether blends area mixture of gasoline and as much as 15% ether. Gaso-line/ether blends can be used in your motorcycle if theether content does not exceed 17%.

● REFORMULATED OR OXYGENATED GASOLINES(RFG): “Reformulated gasoline” is a term used todescribe gasoline blends that are specifically designedto burn cleaner than other types of gasoline, leavingfewer “tailpipe” emissions. They are also formulated toevaporate less when you are filling your tank. Reformu-lated gasolines use additives to “oxygenate” the gas.Your motorcycle will run normally using this type of gas.Buell recommends you use it when possible, as an aid tocleaner air in our environment.

Because of their generally higher volatility, these blends mayadversely affect the starting, driveability and fuel efficiency ofyour motorcycle. If you experience these problems, Buell rec-ommends that you operate your motorcycle on straight,unleaded gasoline.

LUBRICATION

The engine has a force-feed (pressure) type oiling system,incorporating oil feed and return pumps in one pump body,with one check valve on the oil feed side. The feed pumpforces oil to the engine, lubricating lower connecting rod bear-ings, rocker arm bushings, valve stems, valve springs, pushrods and tappets. Cylinder wall, piston, piston pin, timinggears, bushings and main bearings are lubricated by oil spraythrown off connecting rods and crankshaft, and by oil drainingfrom each rocker box through an internal drain passage ineach cylinder and each tappet guide. Oil is transferred to theteeth of all the cam gears by way of the gear meshing action.The oil-scavenging section of the pump returns oil to the tankfrom the engine. See 3.7 LUBRICATION SYSTEM for moreinformation.

ADJUSTMENT/TESTING

General

When an engine needs repair, it is not always possible todetermine definitely beforehand whether repair is possiblewith only cylinder head, cylinder and piston disassembled orwhether complete engine disassembly is required for crank-case repair.

Most commonly, only cylinder head and cylinder repair isneeded (valves, rings, piston, etc.) and it is recommendedprocedure to service these units first, allowing engine crank-case to remain in frame.

See DISASSEMBLING ENGINE FOR CYLINDER HEADREPAIR/ENGINE REMOVAL. under 3.3 STRIPPINGMOTORCYCLE FOR ENGINE REPAIR/REMOVAL to stripmotorcycle for removal of cylinder head, cylinder, and piston.

After disassembling “upper end” only, it may be found thatcrankcase repair is necessary. In this situation, remove theengine crankcase from the chassis.

CAUTION

If engine is removed from chassis, do not lay engine onprimary side. Placing engine on primary side will dam-age clutch cable end fitting. If fitting is damaged, clutchcable must be replaced.

See 1.24 TROUBLESHOOTING section. Symptoms indicat-ing a need for engine repair are often misleading, but gener-ally, if more than one symptom is present, possible causescan be narrowed down to make at least a partial diagnosis.An above-normal consumption of oil, for example, could becaused by several mechanical faults. However, when accom-panied by blue-gray exhaust smoke and low engine compres-sion, it indicates the piston rings need replacing. Lowcompression by itself, however, may indicate improperlyseated valves, in addition to or in lieu of worn piston rings.

Most frequently, valves, rings, pins, bushings, and bearingsneed attention at about the same time. If the possible causescan be narrowed down through the process of elimination toindicate any one of the above components is worn, it is bestto give attention to all of the cylinder head and cylinder parts.

Compression Test Procedure

Combustion chamber leakage can result in unsatisfactoryengine performance. A compression test can help determinethe source of cylinder leakage. Use CYLINDER COMPRES-SION GAUGE (Part No. HD-33223-1).

A proper compression test should be performed with theengine at normal operating temperature when possible. Pro-ceed as follows:


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CAUTION

After completing the compression test(s), make sure thatthe throttle plate is in the closed position before startingengine. Engine will start at an extremely high RPM ifthrottle plate is left open.

1. Disconnect spark plug wire. Clean around plug base andremove plug.

2. Connect compression tester to cylinder.

3. With carburetor throttle plates in wide open position,crank engine continuously through 5-7 full compressionstrokes.

4. Note gauge readings at the end of the first and last com-pression strokes. Record test results.

5. Compression is normal if final readings are 120 psi(827 kPa) or more.

6. Inject approximately 1/2 oz. (15 ml) of SAE 30 oil intocylinder and repeat the compression test. Readings thatare considerably higher during the second test indicateworn piston rings.

Cylinder Leakage Test

The cylinder leakage test pinpoints engine problems includ-ing leaking valves, worn, broken or stuck piston rings andblown head gaskets. The cylinder leakage tester applies com-pressed air to the cylinder at a controlled pressure and vol-ume, and measures the percent of leakage from the cylinder.

Use a CYLINDER LEAKDOWN TESTER (Part No. HD-35667A) and follow the specific instructions supplied with thetester.

The following are some general instructions that apply toBuell motorcycle engines:

1. Run engine until it reaches normal operating tempera-ture.

2. Stop engine. Clean dirt from around spark plug andremove spark plug.

3. Remove air cleaner and set carburetor throttle in wideopen position.

4. Remove timing inspection plug from crankcase.

5. The piston, in cylinder being tested, must be at top deadcenter of compression stroke during test.

6. To keep engine from turning over when air pressure isapplied to cylinder, engage transmission in fifth gear andlock the rear brake.

7. Following the manufacturer’s instructions, perform a cyl-inder leakage test on the front cylinder. Make a note ofthe percent leakdown. Any cylinder with 12% leakdown,or more, requires further attention.

8. See Table 3-2. Listen for air leaks at carburetor intake,exhaust, head gasket and timing inspection hole.

NOTEIf air is escaping through valves, check push rod length.

9. Repeat procedure on rear cylinder.

CAUTION

After completing the compression test(s), make sure thatthe throttle plate is in the closed position before startingengine. Engine will start at an extremely high RPM ifthrottle plate is left open.

Diagnosing Smoking Engine or High Oil ConsumptionPerform COMPRESSION TEST PROCEDURE or CylinderLeakage Test as described previously. If further testing isneeded, remove suspect head(s) and inspect the following:

● Valve guide seals.

● Valve guide-to-valve stem clearance.

● Gasket surface of both head and cylinder.

Table 3-1. Compression Test Results

DIAGNOSIS TEST RESULTS

Ring trouble Compression low on first stroke; tends to build up on the following strokes but does not reach normal; improves considerably when oil is added to cylinder.

Valve trouble Compression low on first stroke; does not build up much on follow-ing strokes; does not improve con-siderably with the addition of oil.

Head gasket leak Same reaction as valve trouble.

Table 3-2. Air Leakage Test

AIR LEAK LOCATION POSSIBLE CAUSES

Carburetor intake Intake valve leaking.

Exhaust pipe Exhaust valve leaking.

Timing inspection hole Piston rings leaking.Worn or broken piston.Worn cylinder.

Head gasket Leaking gasket.


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STRIPPING MOTORCYCLE FOR ENGINE REPAIR/REMOVAL 3.3


DISASSEMBLING ENGINE FOR CYLINDER HEAD REPAIR/ENGINE REMOVAL

1. Lift and secure the motorcycle by placing the vehicle ona lift and anchor rear wheel in place. Raise lift so the topof the cylinder head is easy to access.

2. Remove seat. See 2.28 SEAT.

11WARNING1WARNING

To protect against shock and accidental start-up of vehi-cle, disconnect the negative battery cable before pro-ceeding. Inadequate safety precautions could result indeath or serious injury.

11WARNING1WARNING

Always disconnect the negative first. If the positive cableshould contact ground with the negative cable installed,the resulting sparks may cause a battery explosionwhich could result in death or serious injury.

3. Disconnect both battery cables, negative cable first. See7.16 BATTERY.

4. Remove fuel tank. See 7.16 BATTERY.

5. Remove muffler. See 2.20 EXHAUST SYSTEM.

6. Place jack under the motor. Use jack to lower motor.

7. Remove Horn. See 7.22 HORN.

8. See Figure 3-1. Remove crankcase breather hose andcrankcase breather from rocker box grommet.

CAUTION

See Figure 3-2. Do not attempt to remove isolator mountfrom cylinder head. Isolator mount is an integral compo-nent and is not meant to be removed unless absolutelynecessary. Repeated removals and installations willdamage cylinder head threads.

NOTES:● Remove the isolator mount ONLY to replace the engine,

cylinder head or servicing of exhaust valve components.For all other disassembly and servicing do not removemount from cylinder head.

● Proceed to step 9. for engine removal, cylinder headreplacement or complete cylinder head servicing includ-ing exhaust valve components.

● For all other disassembly and related servicing proce-dures proceed to step 10.

9. See Figure 3-2. Remove the two mounted cylinder headbolts from the front isolator/engine bracket marked “DONOT REMOVE”. See note above.

NOTES:● For top end service proceed to step 11.● For engine removal proceed to step 12.

Figure 3-1. Remove Crankcase Breather Hose

Figure 3-2. Cylinder Head Bolts

7629

7646

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10. See Figure 3-3. Loosen and remove front isolator mountbolt, spacer, snubber and locknut.

11. For top end service loosen, but do not remove lower fronttie bar bolts at engine and frame.

12. For engine removal, loosen and remove lower front tiebar from engine.

13. See Figure 3-4. Remove top rear tie bar at frame.

Figure 3-3. Front Isolator Mount

Figure 3-4. Remove Top Rear Tie Bar

1. Frame2. Locknut3. Snubber4. Bolt5. Spacer6. Front Isolator7. Standoff

1a0162x6x

234

5

6

7

7627


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14. See Figure 3-5. Remove entire air cleaner and carbure-tor as an assembly.

a. Remove screws on both air cleaner brackets.

b. See Figure 3-6. Loosen hose clamp.

c. See Figure 3-7. Remove crankcase breather hose.

d. See Figure 3-8. Disconnect auto enrichener plug.

e. See Figure 3-8. Place air cleaner and carburetor asan assembly on top of frame.

NOTES:

● See 4.3 AIR CLEANER for more details about theair cleaner.

● See 3.5 CYLINDER HEAD. The steps mentionedpreviously complete disassembly preparation for topend servicing. You may now proceed with TOP ENDDISASSEMLY PROCEDURES.

● If continuing engine removal proceed to step 16.

Figure 3-5. Air Cleaner Assembly

1

2

a0074x3x

1. Air cleaner bracket (left front)2. Air cleaner bracket (right rear)3. Air cleaner screw

3

Figure 3-6. Hose Clamp

Figure 3-7. Crankcase Breather Hose

Figure 3-8. Auto Enrichener Plug

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7649

1. Breather Hose2. Three-way Connector

1

2

1. Auto enrichener plug2. Frame

2

1

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NOTEThe remaining steps are required to complete engineremoval.

15. Place jack under the motor. Use jack to lower motor.

16. Move jack forward.

17. Place wooden cradle under engine.

NOTE

See Figure 3-9. Remove rear master cylinder before remov-ing sprocket cover.

18. Remove sprocket cover. See 2.22 SPROCKET COVER.

19. See Figure 3-9. Disconnect screws at brake fluid reser-voir, master cylinder and brake line bracket (items 1, 3and 6).

20. Move belt on rear sprocket off pulley toward inside ofmotorcycle.

21. See Figure 3-10. Remove right side rider footpeg bracketassembly. See 2.21 FOOTPEGS AND FOOTPEG SUP-PORT BRACKETS.

22. Introduce freeplay and remove clutch cable at hand leverlocation. See 6.4 CLUTCH.

23. See Table 3-3. Disconnect the following electrical items:

Figure 3-9. Brake Line Assembly

1. Screw2. Brake fluid reservoir 3. Screw4. Brake line bracket5. Brake line6. Screw7. Master cylinder8. Spacer

1

3

6

78

2 54

a0017x3x

Figure 3-10. Footpeg Bracket Assembly

1. Frame 2. Locknut3. Washer4. Spacer5. Footrest support bracket6. Clevis pin7. Footpeg8. Cotter pin9. Index plate10. Spacer

a0016x3x

1

2

3

4

5

6

8

7

109


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24. See Figure 3-11. Place a floor hoist behind the lift.Attach straps to frame and hoist. Raise hoist until strapstighten.

25. Remove rear shock. See 2.15 REAR SHOCKABSORBER.

26. See Figure 3-12. Loosen nut on hose routing clamp.

Table 3-3. Electrical Items Disconnected for Engine Disassembly

Item no.

Description Location

1 Ignition module [10] Located on frame backbone.

2 Speedo sensor [65] Located under seat (right side-tucked in under cavity).

3 Side stand switch [60] Tie wrapped to rear brake line.

4 Neutral switch [131] Disconnect at neutral switch.

5 Oil pressure switch [120]

Disconnect at oil pressure switch.

6 Alternator stator [46] Located under seat (left side).

7 Starter solenoid wire [128]

Disconnect at starter.

8 Spark plug wire Located on spark plug.

9 Battery—positive wire Disconnect at main circuit breaker.

10 Rear brake light switch [121]

Located under frame by shock absorber.

Figure 3-11. Hoisting Bike

Figure 3-12. Loosen Clamp

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27. See Figure 3-13. Disconnect feed, return, transmissionand crankcase vent lines.

28. See Figure 3-14. Remove rear motor mount bolts.

29. Remove chassis from engine by performing the stepsbelow.

a. Lower chassis.

b. Disconnect hoist from chassis.

c. Lower lift.

d. See Figure 3-15. Lift chassis and roll away fromengine.

Figure 3-13. Disconnect Lines

Figure 3-14. Removing Rear Motor Mount Bolts

Figure 3-15. Move Chassis From Engine

7634

1. Oil Return2. Transmission Vent3. Crankcase Vent4. Oil Feed

4

2

1

3

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30. See Figure 3-16. Remove air cleaner box bracket.

31. See Figure 3-17. Remove rear engine mount.

32. See Figure 3-18. Loosen swingarm pinch bolt.

Figure 3-16. Bracket

Figure 3-17. Rear Engine Mount

Figure 3-18. Pinch Bolt

7652

7653

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33. See Figure 3-19. Remove swingarm pivot shaft and rearwheel as an assembly. See 2.19 SWINGARM.

34. See Figure 3-20. Remove side stand and bracketassembly. See 2.29 SIDE STAND

Figure 3-19. Swingarm Pivot Shaft

Figure 3-20. Side Stand Bracket

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7656


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ENGINE INSTALLATION 3.4

INSTALLING ENGINE

1. Ensure cradle is secured under engine.

2. See Figure 3-21. Install side stand and bracket assem-bly. See 2.29 SIDE STAND.

a. Apply several drops of LOCTITE® THREAD-LOCKER 262 (red) to last few threads.

b. Tighten to 38-41 ft-lbs (51-55 Nm).

3. Install rear wheel. See 2.6 REAR WHEEL.

See Figure 3-22. Install swingarm pivot shaft and rearwheel as an assembly. See 2.19 SWINGARM.

a. Tighten to 24-26 ft-lbs (32-35 Nm).

4. See Figure 3-23. Install swingarm pinch bolt.

a. Apply several drops of LOCTITE® THREAD-LOCKER 243 (blue) to last few threads.

b. Tighten to17-19 ft-lbs (23-26 Nm).

Figure 3-21. Side Stand Bracket

Figure 3-22. Swingarm Pivot Shaft

Figure 3-23. Pinch Bolt

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5. See Figure 3-24. Install rear engine mount.



6. See Figure 3-25. Loosely install air cleaner box bracket.

7. Install chassis onto engine by performing the stepsbelow.

a. See Figure 3-26. Roll chassis toward engine.

b. Lift chassis onto engine.

c. Raise lift.

d. See Figure 3-27. Attach hoist to frame; Place a floorhoist behind the lift. Attach straps to frame andhoist. Raise hoist until straps tighten.

8. Place jack under the motor. Use jack to raise motor.

9. Move jack backward.

Figure 3-24. Rear Engine Mount

Figure 3-25. Bracket

Figure 3-26. Move Chassis to Engine

7653

7652

7651


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10. See Figure 3-28. Install rear motor mount bolts.



11. See Figure 3-29. Connect feed, return, transmission andcrankcase vent lines.

Figure 3-27. Hoisting Bike

Figure 3-28. Installing Rear Motor Mount Bolts

Figure 3-29. Connect Lines

7650

7623

7634

1. Oil return2. Transmission vent3. Crankcase vent4. Feed

4

2

1

3


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12. See Figure 3-30. Tighten hose clamps using HoseClamp Pliers, part no. HD-41137.

13. See Figure 3-31. Tighten nut on hose routing clamp.

14. Install rear shock. See 2.15 REAR SHOCK ABSORBER.

15. See Table 3-4. Electrical Items for Engine AssemblyConnect the following electrical items:

Figure 3-30. Tighten Hose Clamps

Figure 3-31. Tighten Clamp

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7718

Table 3-4. Electrical Items for Engine Assembly

Item no.

Description Location

1 Ignition module [10] Located on frame backbone.

2 Speedo sensor [65] Located under seat (right side-tucked in under cavity).

3 Side stand switch [60] Tie wrapped to rear brake line.

4 Neutral switch [131] Disconnect at neutral switch.

5 Oil pressure switch [120] Disconnect at oil pressure switch.

6 Alternator stator [46] Located under seat (left side).

7 Starter solenoid wire [128]

Disconnect at starter.

8 Spark plug wire Located on spark plug.

9 Battery—positive wire Disconnect at main circuit breaker.

10 Rear brake light switch [121]

Located under frame by shock absorber.


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16. Install clutch cable at hand lever location. See 6.4CLUTCH.

17. Install drive belt. See 1.11 DRIVE BELT AND REARSPROCKET.

18. Install front sprocket cover. See 2.22 SPROCKETCOVER.

19. Install master cylinder onto footpeg bracket. See 2.21FOOTPEGS AND FOOTPEG SUPPORT BRACKETS.



NOTE:SEE TOP END ASSEMBLY SECTION. The steps mentionedpreviously complete Assembly preparation for top end servic-ing. You may now proceed with TOP END ASSEMBLY PRO-CEDURES. Then proceed to step 22.

Figure 3-32. Brake Line Assembly

Figure 3-33. Footpeg Bracket Assembly

1. Screw2. Brake Fluid Reservoir 3. Screw4. Brake Line Bracket5. Screw6. Brake Line7. Master Cylinder8. Spacer

1

3

6

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20. See Figure 3-34. Connect auto enrichener plug.

21. See Figure 3-36. Install entire air cleaner assembly. See4.3 AIR CLEANER.

c. See Figure 3-35. Connect crankcase breather hoseto three-way connector.

d. See Figure 3-37.Install hose clamp.

e. See Figure 3-36. Install and tighten screws on bothair cleaner brackets.

f. Install screw on air cleaner cover.

NOTESee 4.3 AIR CLEANER for more details on the air cleaner.

Figure 3-34. Auto Enrichener Plug

Figure 3-35. Crankcase Breather Hose

1. Auto Enrichener Plug2. Frame

2

1

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7649

1. Breather Hose2. Three-way Connector

1

2

Figure 3-36. Air Cleaner Assembly

Figure 3-37. Hose Clamp

1. Air Cleaner Bracket (left front)2. Air Cleaner Bracket (right rear)3. Air Cleaner Screw

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22. See Figure 3-38. Install top rear tie bar at frame.

23. Tighten tie bar bolt to 30-33 ft-lbs (41-45 Nm).

24. Install ground strap bolt to engine. Tighten ground strapbolt to 30-33 ft-lbs (41-45 Nm).

25. See Figure 3-39. Install front tie bar onto engine.



26. See Figure 3-40. Install the two mounted cylinder headbolts from the front isolator/engine bracket marked “DONOT REMOVE”.

a. Apply several drops of LOCTITE® THREAD-LOCKER 262 (red) to last few threads of new bolts.

b. Apply a thin film of clean HD 20W50 engine oil toboth sides of new thick washers and to bottom ofbolt heads. Exercise caution to avoid mixing oil onwashers with LOCTITE on bolts.

c. Tighten bolts to 60 ft-lbs (27 Nm) initially and thenloosen each bolt one full turn. Tighten bolts again to60 ft-lbs (27 Nm).

Figure 3-38. Install Top Rear Tie Bar

Figure 3-39. Install Front Tie Bar

Figure 3-40. Cylinder Head Bolt

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27. See Figure 3-41. Install front isolator mounting bolt,spacer snubber and new nut.

28. Tighten front isolator mounting bolt to 63-70 ft-lbs (86-95Nm).

29. See Figure 3-42. Install crankcase breather hose andcrankcase breather into rocker box grommet.

30. Install horn. See 7.22 HORN.

31. Remove jack from under the motor.

32. Install muffler. See 2.20 EXHAUST SYSTEM.

33. Install fuel tank. See 4.2 FUEL TANK COVER/FUELTANK.

34. Install new oil filter, engine oil and primary chaincasefluid as necessary.

35. See Figure 3-33. Install right side rider footpeg bracketassembly. See 2.21 FOOTPEGS AND FOOTPEG SUP-PORT BRACKETS.

11WARNING1WARNING

Always connect positive battery cable first. If the positivecable should contact ground with the negative cableinstalled, the resulting sparks may cause a battery explo-sion which could result in death or serious injury.

36. Connect both battery cables, positive cable first. See7.16 BATTERY.

37. Install seat. See 2.28 SEAT.

Figure 3-41. Front Isolator Mount

Figure 3-42. Install Crankcase Breather Hose

1. Frame2. Locknut3. Snubber4. Bolt5. Spacer6. Front Isolator7. Standoff

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CYLINDER HEAD 3.5

REMOVAL

Before removing the cylinder head assembly, see 3.3 STRIP-PING MOTORCYCLE FOR ENGINE REPAIR/REMOVAL.The rocker arm covers and internal components must beremoved before removing cylinder head.

1. See Figure 3-43. Remove screws with washers and fiberseals. Discard fiber seals.

CAUTION

Do not mix or replace hardened washers and fastenerswith unhardened parts. Do not reuse fiber cover seals.These actions may result in accelerated wear andincreased noise.

2. Remove rocker cover.

3. Remove and discard gaskets.

4. Rotate crankshaft until piston on head reaches top deadcenter of compression stroke.

5. Remove spark plug.

NOTEBoth valves in the cylinder head will be closed when viewedthrough the spark plug hole.

6. Remove the two rocker arm retaining bolts near the pushrods.

7. Remove remaining hardware holding lower rocker coverto cylinder head in the following order.

a. Remove two screws and washers.

b. Remove three bolts and washers.

c. Remove the remaining two rocker arm retainingbolts.

Figure 3-43. Rocker Arm Cover

1. Crankcase Breather2. Grommet3. Screw (4)4. Gasket5. Rocker Cover (top)6. Bolt (3) 7. Washer (3)8. Rocker Arm Shafts9. Bolt w/washer (2)10. Rocker Cover (lower)11. Rocker Arm (exhaust)12. Bushing (rocker arm)13. Gasket (valve side)14. Gasket (push rod side)15. Hydraulic Lifter16. Gasket (push rod cover)17. Screw (4)18. O-ring (push rod cover)19. Push Rod (exhaust)20. Anti-Rotation Screw (2) 21. Push Rod cover22. Washer (4)23. Bolt (2)24. Rocker Arm (intake)25. Gasket (lower)26. Bolt (2)27. Gasket (inner)

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8. See Figure 3-43. Remove lower rocker cover.

NOTE

Remove lower rocker box as an assembly; then disassembleas required.

9. Mark the location and orientation (top/bottom) of eachpush rod. Remove push rods.

CAUTION

Mark rocker arm shafts for reassembly in their originalpositions. Valve train components must be reinstalled intheir original positions to prevent accelerated wear andincreased valve train noise.

10. See Figure 3-44. Remove rocker arm shafts by tappingthem out using a hammer and a soft metal punch.

11. See Figure 3-43. Remove rocker arms; mark them forreassembly in their original locations.

CAUTION

Distortion to the head, cylinder and crankcase studs mayresult if head screws are not loosened (or tightened)gradually in the sequence shown in Figure 3-45.

12. See Figure 3-45. Loosen each head screw 1/8-turn fol-lowing the sequence shown.

13. Support motorcycle under crankcase. Do not allowengine to drop when performing the next Step.

14. Continue loosening in 1/8-turn increments until screwsare loose. Remove head screws.

15. Remove cylinder head, head gasket, and O-rings.

16. Discard head gasket.

17. See Figure 3-43. Remove push rod cover, gasket andvalve tappets.

DISASSEMBLY

1. See Figure 3-46. Compress valve springs with VALVESPRING COMPRESSOR (Part No. HD-34736B).

2. See Figure 3-47. Remove valve keepers, upper collarand valve springs. Mark valve keepers for reassembly intheir original locations.

3. Use a fine tooth file to remove any burrs on the valvestem at the keeper groove.

4. Mark valve to ensure that it will be reassembled in thesame head. Remove valve, valve stem seal and lowercollar.

5. Repeat the above procedure for the other valve.

Figure 3-44. Removing Rocker Arm Shafts (Typical)

Figure 3-45. Head Screw Loosening/Tightening Sequence

Figure 3-46. Valve Spring Compressor (Part No. HD-34736B)

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2

1. Position of rocker arm retaining bolts2. Retaining notch

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Figure 3-47. Cylinder Head, Cylinder and Piston Assembly

1. Screw2. Screw3. Valve collar retainer4. Upper valve spring collar5. Inner valve spring6. Outer valve spring7. Valve seal8. Lower valve spring collar9. Valve guide intake & exhaust (2)10. Cylinder head11. Exhaust port stud12. Cylinder head gasket13. Cylinder O-ring (4)14. Cylinder insert15. Cylinder w/piston & rings16. Cylinder base gasket17. Cylinder base stud18. Exhaust valve19. Exhaust valve seat

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CLEANING AND INSPECTION

1. Bead blast or scrape carbon from head, top of cylinderand valve ports. Be careful to avoid scratching or nickingcylinder head and cylinder joint faces. Blow off loosenedcarbon or dirt with compressed air.

2. Soak cylinder head in an aluminum-compatible cleaner/solvent to loosen carbon deposits.

3. Wash all parts in non-flammable solvent, followed by athorough washing with hot, soapy water. Blow out oilpassages in head. Be sure they are free of sludge andcarbon particles. Remove loosened carbon from valvehead and stem using a wire wheel. Never use a file orother hardened tool which could scratch or nick valve.Polish valve stem with very fine emery cloth or steelwool.

4. Check each rocker arm, at pad end and push rod end,for uneven wear or pitting. Replace rocker arm if eithercondition exists.

5. Measure and record rocker arm shaft diameter.

a. See Figure 3-48. Measure where shaft fits in lowerrocker arm cover.

b. See Figure 3-49. Measure where rocker arm bush-ings ride.

6. Measure and record rocker arm shaft bore diameter.

a. See Figure 3-50. Measure bore of lower rockercover.

b. See Figure 3-51. Measure rocker arm bushing innerdiameter.

Figure 3-48. Measuring Rocker Arm Shaft Diameter(Rocker Cover Position)

Figure 3-49. Measuring Rocker Arm Shaft Diameter(Rocker Arm Bushing Position)

Figure 3-50. Measuring Rocker Arm Shaft Bore Diameter in Lower Rocker Cover

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7. Check the measurements obtained in Steps 5-6 againstthe SERVICE WEAR LIMITS. Repair or replace partsexceeding limits.

8. Assemble rocker arms and rocker arm shafts into lowerrocker cover.

9. Check end play of rocker arm with feeler gauge.

10. Replace rocker arm or lower cover or both if end playexceeds 0.025 in. (0.635 mm).

11. Valve heads should have a seating surface width of0.040-0.062 in. (1.016-1.575 mm), and should be free ofpit marks and burn spots. The color of carbon on exhaustvalves should be black or dark brown. White or light buffcarbon indicates excessive heat and burning.

12. Valve seats are also subject to wear, pitting, and burning.Resurface valve seats whenever valves are refinished.

13. Clean valve guides by lightly honing with VALVE GUIDEHONE (Part No. HD-34723).

14. Scrub guides with VALVE GUIDE BRUSH (Part No. HD-34751) and hot soapy water. Measure valve stem outerdiameter and valve guide inner diameter. Check mea-surements against SERVICE WEAR LIMITS.

15. Inspect spark plug threads for damage. If threads inhead are damaged, a special plug type insert can beinstalled using a 12 mm spark plug repair kit.

16. Inspect valve springs for broken or discolored coils.

17. See Figure 3-52. Check free length and compressionforce of each spring. Compare with SERVICE WEARLIMITS. If spring length is shorter than specification or ifspring compression force is below specification, replacespring.

18. Examine push rods, particularly the ball ends. Replaceany rods that are bent, worn, discolored or broken.

19. See Figure 3-53. Check head gasket surface on head forflatness. Machine or replace any head which exceedsSERVICE WEAR LIMIT of 0.006 in. (0.152 mm).

Figure 3-51. Measuring Rocker Arm BushingInner Diameter

Figure 3-52. Checking Spring Free Length

Figure 3-53. Checking Gasket Surface

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Rocker Arms and Bushings1. See Figure 3-54. To replace worn bushings, press or

drive them from the rocker arm. If bushing is difficult toremove, turn a 9/16-18 tap into bushing. From oppositeside of rocker arm, press out bushing and tap.

2. Press replacement bushing into rocker arm, flush witharm end, and split portion of bushing towards top of arm.

3. Using remaining old bushing as a pilot, line ream newbushing with ROCKER ARM BUSHING REAMER (PartNo. HD-94804-57).

4. Repeat for other end of rocker arm.

Figure 3-54. Removing Rocker Arm Bushing

9/16 in. -18 tap

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Replacing Valve Guides

Valve guide replacement, if necessary, must be done beforevalve seat is ground. It is the valve stem hole in valve guidethat determines seat grinding location. Valve stem-to-valveguide clearances are listed in Table 3-5. If valve stems and/orguides are worn beyond limits, install new parts.

1. To remove shoulderless guides, press or tap guidestoward combustion chamber using DRIVER HANDLEAND REMOVER (Part No. HD-34740).

2. Clean and measure valve guide bore in head.

3. Measure outer diameter of a new standard valve guide.The guide diameter should be 0.0020-0.0033 in.(0.0508-0.0838 mm). larger than bore in head. If it is not,select one of the following oversizes: +0.001 in. (+0.025mm), +0.002 in. (+0.051 mm) or +0.003 in. (+0.076 mm)(intake and exhaust).

4. See Figure 3-55. Install shoulderless guides usingVALVE GUIDE INSTALLATION TOOL (Part No. HD-34731) and DRIVER HANDLE (Part No. HD-34740).Press or drive guide until the tool touches the machinedsurface surrounding the guide. At this point, the correctguide height has been reached.

5. Ream guides to final size or within 0.0010 in.(0.0254 mm) of final size using VALVE GUIDE REAMER(Steel, Part No. HD-39932 or Carbide, Part No. HD-39932-CAR). Use REAMER LUBRICANT (Part No. HD-39964) or liberal amounts of suitable cutting oil to pre-vent reamer chatter.

NOTE

The hone is not intended to remove material.

6. Apply the proper surface finish to the valve guide boresusing the VALVE GUIDE HONE (Part No. HD-34723).Lubricate hone with honing oil. Driving hone with anelectric drill, work for a crosshatch pattern with an angleof approximately 60°.

7. See Figure 3-56. Thoroughly clean valve guide boresusing VALVE GUIDE BRUSH) (Part No. HD-34751) andhot soapy water.

Table 3-5. Valve Stem Clearancesand Service Wear Limits

VALVE CLEARANCESERVICE WEAR

LIMIT

Exhaust 0.0015-0.0033 in.(0.0381-0.0838 mm)

0.0040 in.(0.1016 mm)

Intake 0.008-0.0026 in.(0.203-0.0660 mm)

0.0035 in.(0.0889 mm)

Figure 3-55. Installing Shoulderless Valve Guide

Figure 3-56. Cleaning Valve Guides

5692

1. Driver Handle (Part No. HD-34740)2. Valve Guide Installation tool (Part No. HD-34731)3. Cylinder Head Stand (Part No. HD-39782)

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3

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1. Valve Guide Brush (Part No. HD-34751)2. Cylinder Head Holding Fixture

(Part No. HD-39786)

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Grinding Valve Faces and Seats

After installing valve guides, reface valve seats to make themconcentric with guides.

See Figure 3-57. Valve face angle is 45° for both intake andexhaust valves. If a valve re-facing grinder is used, it must beadjusted exactly to this angle.

NOTES

● It is important to remove no more metal than is neces-sary to clean up and true valve face.

● Install a new valve if grinding leaves the valve edge(the margin) with a width of less than 1/32 in. (0.8mm).

CAUTION

Do not use valves with too thin of margins. Using a valvewith too thin a margin does not seat normally, burns eas-ily, may cause pre-ignition and can also lead to valvecracking.

● Valves that do not clean up quickly are probablywarped or too deeply pitted to be reused.

● Replace the valve if end of valve stem shows unevenwear.

● After valves have been ground, handle with care toprevent damage to the ground faces.

The valve seats may be refinished with cutters or grinders.Cut seats to a 46° angle or grind seats to a 45° angle.

See Table 3-6. Valve seat tools and fixtures are availablecommercially. Seat each valve in the same position fromwhich it was removed.

The correct 3-angle valve seat angles are as shown. UseNEWAY VALVE SEAT CUTTER SET (Part No. HD-35758) tocut the seats. Always grind valves before cutting seats.

1. See Figure 3-58. Cut 46° (or grind 45°) valve seat anglefirst. Use cutting oil to avoid chatter marks. Cut or grindonly enough to clean up the seat.

2. Apply a small amount of lapping compound to the valveface. Rotate valve against seat using VALVE LAPPINGTOOL (Part No. HD-96550-36A).

3. See Figure 3-57. Check the contact pattern on valveface. It should be 0.040-0.062 in. (1.016-1.575 mm)wide, and its center should be positioned 2/3 of the waytoward the outside edge of face.

4. If valve seat pattern is too close to the stem side of valveface, cut a 60° angle in order to raise seat. If pattern istoo close to the edge of valve face, cut a 31° angle inorder to lower seat.

5. After cutting either or both 31° or 60° angles to positionseat, final cut 46° (or grind 45°) seat angle to obtainproper 0.040-0.062 in. (1.016-1.575 mm) width.

6. Recheck valve seat width and location with lapping com-pound as described in Step 2.

7. To achieve a smooth even finish, place a piece of 280 gritemery paper under the cutter head and rotate cutter.

CAUTION

Do not grind valve to shorten. Grinding will remove thecase hardening and expose the stem’s mild steel coreresulting in rapid end wear.

8. See Figure 3-59. Wipe valve seats and valve facesclean. Measure valve stem protrusion.

a. If valve stem protrudes more than 2.031 in.(51.587 mm), replace valve seat or cylinder head.

b. If valve stem protrusion is acceptable, valves andseats are ready for lapping.

Figure 3-57. Valve Seat Angles

Table 3-6. Neway Valve Seat Cutters

VALVE SEAT 60° CUTTER31° AND 46° CUTTERS

Exhaust Part No. 205 Part No. 622

Intake Part No. 293 Part No. 642

Figure 3-58. Valve Seat Cutter

Head

Valve

46° Cutting45° Grinding

Seat

31°

0.040-0.062 in.(1.016-1.575 mm)

60°

Margin

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Replacing Valve SeatsReplacing a valve seat is a complex operation requiring spe-cial equipment. If the seat is loose or is not fully seated in thehead, then seat movement will prevent the proper transfer ofheat from the valve. The seat surface must be flush with (orbelow) the head surface. See 3.1 SPECIFICATIONS for valveseat-to-cylinder head fit.

To remove the old seat, lay a bead of weld material aroundthe inside diameter of the seat. This will shrink the seat out-side diameter and provide a surface for driving the seat outthe port side.

Lapping Valve Faces and SeatsNOTE

If valve faces and seats have been smoothly and accuratelyrefaced, very little lapping will be required to complete theseating operation.

1. See Figure 3-60. Use CYLINDER HEAD HOLDING FIX-TURE (Part No. HD-39786) to secure cylinder head.

a. Apply a light coat of fine lapping compound to valveface. Insert valve in guide.

b. Place one rubber cup end of VALVE LAPPINGTOOL (Part No. HD-96550-36A) onto head of valve.

c. Holding lapping tool as shown, apply only very lightpressure against valve head.

d. Rotate lapping tool and valve alternately clockwiseand counterclockwise a few times.

2. Lift valve and rotate it about 1/3 of a turn clockwise.Repeat lapping procedure in Step 1.

3. Repeat Step 2. Then, remove valve.

4. Wash valve face and seat. Dry parts with a new, cleancloth or towel.

5. Inspect valve and seat.

a. If inspection shows an unbroken lapped finish of uni-form width around both valve and seat, valve is wellseated.

b. If lapped finish is not complete, further lapping (orgrinding and lapping) is necessary.

Figure 3-59. Measuring Valve Stem Protrusion

Figure 3-60. Lapping Valves

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5693 Valve Lapping Tool(HD-96550-36A)

Cylinder Head Holding Fixture(HD-39786)


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ASSEMBLY

CAUTION

Make sure all lapping compound is removed from cylin-der head and valves after lapping is completed. If lappingcompound contaminates any internal engine compo-nents or engine oil, excessive engine wear and damagemay result.

1. Wash cylinder head and valves in warm, soapy water toremove all lapping compound.

2. Scrub valve guide bores with VALVE GUIDE BRUSH(Part No. HD-34751) and hot, soapy water.

3. Blow dry with compressed air.

4. Apply a liberal amount of engine oil to the valve stem.

5. See Figure 3-61. Insert valve into valve guide and installlower collar.

6. See Figure 3-62. Place a protective sleeve over the valvestem keeper groove. Coat the sleeve with oil and place anew seal over the valve stem.

CAUTION

● Always use a protective sleeve on the valve stemkeeper groove when installing valve stem seal. If theseal is installed without using the protective sleeve,the seal will be damaged.

● Do not remove valve after seal is installed. Other-wise, sharp edges on keeper groove will damageseal.

7. See Figure 3-61. Tap the valve stem seal onto the valveguide using the VALVE SEAL INSTALLATION TOOL(Part No. HD-34643A) and DRIVER HANDLE (Part No.HD-34740). The seal is completely installed when thetool touches the lower collar.

8. See Figure 3-62. Install valve springs and upper collar.

9. Compress springs with VALVE SPRING COMPRESSOR(Part No. HD-34736B).

10. Insert valve keepers into upper collar, making sure theyengage groove in valve stem. The keeper gaps shouldbe equal.

11. Release and remove VALVE SPRING COMPRESSOR.

12. Repeat Steps 4-11 for the remaining valve.

Figure 3-61. Valve Seal Installation

Figure 3-62. Valve Guide Seal Protector Sleeve

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INSTALLATION

If only cylinder head work was needed, reinstall cylinder headfollowing these instructions. If further repair is required, see3.6 CYLINDER AND PISTON.

1. Coat mating surfaces of cylinder studs and head screwswith parts cleaning solution.

2. Scrape old oil and any carbon deposits from threads byusing a back-and-forth motion, threading each headscrew onto its mating cylinder stud.

3. Remove head screws from studs. Wipe or blow drythread surfaces.

4. Apply oil to stud threads and to the underside of thehead screw shoulder.

CAUTION

Only oil film must remain on the head screw surfaces.Too much oil will pool in the head screw sleeve. Pooledoil may prevent proper torque application and full threadengagement.

5. Blow or wipe off excess oil from head screws.

6. Thoroughly clean and dry the gasket surfaces of cylinderand cylinder head.

7. Install a new O-ring on each dowel.

CAUTION

O-rings help to properly position the head gasket. O-rings must be installed before the head gasket.

8. Install a new head gasket to cylinder.

9. Carefully lower cylinder head over studs and position ondowels. Use great care so as not to disturb head gasket.

CAUTION

The procedure for tightening the head screws is criticalto proper distribution of pressure over gasket area. Itprevents gasket leaks, stud failure, and head and cylin-der distortion.

10. See Figure 3-45. For each cylinder head, start withscrew numbered one, as shown. In increasing numericalsequence (i.e. – 1, 2, 3 and 4):

a. Tighten bolts to 8-10 ft-lbs (11-14 Nm).

b. Tighten bolts to 13-15 ft-lbs (18-20 Nm).

c. Loosen all screws.

11. After screws are loosened from initial torque, tightenhead screws in three stages. Tighten fasteners inincreasing numerical sequence (i.e. – 1, 2, 3 and 4).

a. Tighten each screw to 8-10 ft-lbs (11-14 Nm).

b. Tighten each screw to 13-15 ft-lbs (18-20 Nm).

c. See Figure 3-63. Mark cylinder head and headscrew shoulder with a line as shown (View A).

d. Turn all bolts an additional 85 -95 .

12. See 3.15 HYDRAULIC LIFTERS. Install hydraulic liftersand push rod cover.

13. See Figure 3-64. See Table 3-7.Identify push rod colorcoding, length and respective push rod positions in

engine. Place intake and exhaust push rods onto seat attop of tappet.

° °

Figure 3-63. Tightening Head Screws

Figure 3-64. Push Rod Locations

Table 3-7. Push Rod Selection

Position Color Code LengthPart Num-

ber

Exhaust1 Band-Black

10.800 in.(274.320 mm)

17895-00Y

Intake1 Band-Orange

10.746 in.(272.948 mm)

17984-00Y

ViewA

ViewB

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1. Intake Push Rod2. Exhaust Push Rod

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14. See Figure 3-65. Install new gaskets with the bead fac-ing up. Place lower rocker box assembly (with rockerarms and shafts into position). Place push rods in rockerarm sockets.

CAUTION

Do not turn engine over until both push rods can beturned with fingers. Otherwise, damage to push rods orrocker arms may result.

15. See Figure 3-66. Install fasteners. Slowly snug all fasten-ers in small increments (one turn at a time). Use a crosspattern on the four large bolts) that fasten the lowerrocker box to head. This will bleed the tappets. Fastenersizes and torque specifications are listed in Table 3-8.

a. Tighten bolts to 18-22 ft-lbs (24-30 Nm).

b. Tighten bolts to 11-13 ft-lbs (15-18 Nm).

c. Tighten bolts to 135-155 in-lbs (15-18 Nm).

16. See Figure 3-65. Install upper rocker covers.

a. Place a new inner gasket on lower rocker boxassembly.

b. Place a new lower gasket on lower rocker cover.

c. Install upper rocker cover using screws with wash-ers and new fiber seals. Tighten screws to 10-14 ft-lbs (13.6-9 Nm).

Table 3-8. Lower Rocker Box Hardware

ITEM SIZE TORQUE

Bolt withwasher (12)

5/16-18 X 2-3/418-22 ft-lbs (24-30 Nm)Bolt with

washer (13)5/16-18 X 2-1/2

Screw withwasher (14)

1/4-20 X 1-1/2135-155 in-lbs

(15-18 Nm)

Bolt withwasher (15)

1/4-20 X 1-1/411-13 ft-lbs(15-18 Nm)

Figure 3-65. Rocker Arm Cover Gaskets

Figure 3-66. Lower Rocker Box Fasteners

1. Crankcase Breather2. Grommet3. Screw (4)4. Gasket5. Rocker Cover (top)6. Bolt (3) 7. Washer (3)8. Bolt w/washer (2)9. Rocker Cover (lower)10. Gasket (valve side)11. Gasket (push rod side)12. Washer (4)13. Bolt (2)14. Gasket (lower)15. Washer (4)16. Bolt (2)17. Gasket (inner)

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CYLINDER AND PISTON 3.6

REMOVAL/DISASSEMBLY

1. See 3.3 STRIPPING MOTORCYCLE FOR ENGINEREPAIR/REMOVAL. Strip motorcycle as describedunder this procedure.

2. Remove cylinder head. See 3.5 CYLINDER HEAD.

3. Clean crankcase around cylinder base to prevent dirtand debris from entering crankcase while removing cyl-inder.

4. See Figure 3-67. Turn engine over until piston of cylinderbeing removed is at bottom of its stroke.

5. Carefully raise cylinder just enough to permit placingclean towel under piston to prevent any foreign matterfrom falling into crankcase.

NOTE

If cylinder does not come loose, lightly tap a plastic hammerperpendicular to the cylinder fins. Never try to pry a cylinderup.

6. Carefully lift cylinder over piston and cylinder studs. Donot allow piston to fall against cylinder studs. Discard cyl-inder base gasket.

CAUTION

With cylinder removed, be careful not to bend the cylin-der studs. The slightest bend could cause a stress riserand lead to stud failure.

7. Install a 6.0 in. (152 mm) length of 1/2 in. (12.7 mm) IDplastic or rubber hose over each cylinder stud. This willprotect the studs and the piston.

11WARNING1WARNING

Retaining rings are highly compressed in the ring grooveand may “fly out” with considerable force when priedout. Always wear safety glasses or goggles when remov-ing or installing retaining rings. Failure to wear safetyglasses or goggles could result in death or seriousinjury.

CAUTION

DO NOT re-use piston pin retaining rings. Removal mayweaken retaining rings and they may break or dislodge ifreinstalled resulting in engine damage.

8. Insert an awl in the recessed area below the piston pinbore and pry out the piston pin retaining rings. To preventthe ring from flying out, place your thumb over the retain-ing ring.

Figure 3-67. Cylinder and Piston

1. Ring Set2. Retaining Ring (2)3. Piston4. Dowel and O-ring5. Cylinder6. Cylinder Stud (4)7. Base Gasket8. Piston Pin Bushing9. Connecting Rod10. Piston Pin

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NOTESince the piston pin is a loose fit in the piston, the pin willeasily slide out. The pin has tapered ends to help seat theround retaining rings.

9. See Figure 3-68. The arrow at the top of pistons mustalways point toward the front of the engine.

CAUTION

Handle the piston with extreme care. The alloy used inthese pistons is very hard. Any scratches, gouges orother marks in the piston could score the cylinder duringengine operation and cause engine damage.

10. See Figure 3-68. Spread piston rings outward until theyclear grooves in piston and lift off.

CLEANING AND INSPECTION

1. Soak cylinder and piston in an aluminum-compatiblecleaner/solvent until deposits are soft, then clean with abrush. Blow off loosened carbon and dirt particles andwash in solvent.

2. Clean oil passage in cylinder with compressed air.

3. Clean piston ring grooves with a piece of compressionring ground to a chisel shape.

4. Examine piston pin to see that it is not pitted or scored.

5. Check piston pin bushing to see that it is not loose inconnecting rod, grooved, pitted or scored.

a. A piston pin properly fitted to upper connecting rodbushing has a 0.00125 to 0.00175 in. (0.03175-0.04445 mm) clearance in bushing.

b. See Connecting Rod Bushing section. If piston pin-to-bushing clearance exceeds 0.00200 in. (0.05080mm), replace worn parts.

6. Clean piston pin retaining ring grooves.

7. Examine piston and cylinder for cracks, burnt spots,grooves and gouges.

8. Check connecting rod for up and down play in lowerbearings. When up and down play is detected, lowerbearing should be refitted. This requires removing anddisassembling engine crankcase.

Checking Gasket Surface

CAUTION

If cylinder gasket surface does not meet flatness specifi-cations, replace cylinder and piston. Proper toleranceswill extend component life and prevent leaks.

1. See Figure 3-69. Check cylinder head gasket surface forflatness.

a. Lay a straightedge across the surface.

b. Try to insert a feeler gauge between the straight-edge and the gasket surface.

c. If cylinder head gasket surface is not flat within0.006 in. (0.152 mm), replace cylinder and piston.

2. Check cylinder base gasket surface for flatness.

a. Lay a straightedge across the surface.

b. Try to insert a feeler gauge between the straight-edge and the gasket surface.

c. If cylinder base gasket surface is not flat within0.008 in. (0.203 mm), replace cylinder and piston.

Figure 3-68. Piston Pin and Piston Identification

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V-groove

Figure 3-69. Checking Gasket Surfaces

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Measuring Cylinder Bore 1. Remove any burrs from the cylinder gasket surfaces.

2. See 3.5 CYLINDER HEAD. See Figure 3-70. Install ahead and base gasket, and CYLINDER TORQUEPLATES (Part No. HD-33446A) and XL EVOLUTIONTORQUE PLATE BOLTS (Part No. HD-33446-86).Tighten the bolts using the same method used wheninstalling the cylinder head screws.

NOTETorque plates, properly tightened and installed with gaskets,simulate engine operating conditions. Measurements willvary as much as 0.001 in. (0.025 mm) without torque plates.

3. Take cylinder bore measurement in ring path, startingabout 1/2 in. (12.7 mm) from top of cylinder, measuringfrom front to rear and then side to side. Record readings.

4. Repeat measurement at center and then at bottom ofring path. Record readings. This process will determine ifcylinder is out-of-round (or “egged”) and will also showany cylinder taper or bulge.

5. See Table 3-9. If cylinder is not scuffed or scored and iswithin service limit, see FITTING CYLINDER TO PIS-TON section.

NOTESee 3.1 SPECIFICATIONS. If piston clearance exceeds ser-vice wear limit, cylinders should be re-bored and/or honed tonext standard oversize, and refitted with the correspondingpiston and rings. Do not fit piston tighter than 0.0007 in.(0.0178 mm).

Measuring PistonBecause of their complex shape, the pistons cannot be accu-rately measured with standard measuring instruments.

Pistons have an elliptical shape when viewed from the topand are barrel-shaped when viewed from the side. This barrelshape is not symmetrical.

Any damage to the piston will change its shape, which willlead to problems.

Figure 3-70. Measuring Cylinder Bore Using Torque Plates (Part No. HD-33446A)

Table 3-9. Cylinder Bore Service Wear Limits

BORE SIZES IN. MM

Standard Bore 3.5008 88.9203

0.005 in. OS bore(0.127 mm)

3.5050 89.0270

0.010 in. OS bore(0.254 mm)

3.5100 89.1540

0.020 in. OS bore(0.508 mm)

3.5200 89.4080

0.030 in. OS bore(0.762 mm)

3.5300 89.6620

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Fitting Cylinder to PistonSince pistons cannot be accurately measured with standardmeasuring instruments, the bore sizes must be measured.Bore sizes are listed in Table 3-10. Example: A 0.005 in.(0.127 mm) oversize piston will have the proper clearancewith a bore size of 3.502 in. ± 0.0002 in. (88.951 mm ±0.0051 mm).

Boring and Honing CylinderWhen cylinder requires oversize reboring to beyond 0.030 in.(0.762 mm), the oversize limit has been exceeded and cylin-der must be replaced.

1. Bore cylinder with gaskets and torque plates attached.Bore to 0.003 in. (0.076 mm) under the desired finishedsize.

2. Hone the cylinder to its finished size using a 280 grit rigidhone followed by a 240 grit flexible ball hone. Honingmust be done with the torque plates attached. All honingmust be done from the bottom (crankcase) end of thecylinder. Work for a 60° crosshatch pattern.

Fitting Piston RingsSee Figure 3-71. Piston rings are of two types: compressionand oil control. The two compression rings are positioned inthe two upper piston ring grooves. The dot on the secondcompression ring must face upward. Ring sets are availableto fit standard and oversize pistons.

Piston ring sets must be properly fitted to piston and cylinder:

1. See 3.1 SPECIFICATIONS. See Figure 3-72. Place pis-ton in cylinder about 1/2 in. (12.7 mm) from top. Set ringto be checked squarely against piston as shown. Checkend gap with thickness gauge.

NOTESee SERVICE WEAR LIMITS for end gap dimensions. Donot file rings to obtain proper gap.

Figure 3-71. Piston Rings

Table 3-10. Final Cylinder Bore Sizes

BORE SIZES IN. MM

Standard bore* 3.4978 in. 88.8441 mm

0.005 in. OS bore (0.127 mm) 3.502 in. 88.951 mm

0.010 in. OS bore (0.254 mm) 3.507 in. 89.078 mm

0.020 in. OS bore (0.508 mm) 3.517 in. 89.332 mm

0.030 in. OS bore (0.762 mm) 3.527 in. 89.586 mm

*All bore sizes + 0.0002 in. (0.0051 mm)

Figure 3-72. Measuring Ring End Gap

1. Top Compression Ring – Install either side up2. Second Compression Ring – Install dot toward

top3. Oil Control Rings

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NOTEThe same piston may be used if cylinder bore was notchanged, unless it is scuffed or grooved. If re-using piston,replace piston rings and hone the cylinder walls with a No.240 grit flexible hone to facilitate ring seating.

2. See Figure 3-73. Apply engine oil to piston grooves. UseTRANSMISSION SHAFT RETAINING RING PLIERS(Part No. J-5586) to slip compression rings over pistoninto their respective grooves. Be extremely careful not toover expand, twist rings or damage piston surface wheninstalling rings.

NOTEInstall second compression ring with dot towards top.

3. See Figure 3-74. Install rings so end gaps of adjacentrings are a minimum of 90° apart. Ring gaps are not tobe within 10° of the thrust face centerline.

4. See 3.1 SPECIFICATIONS. See Figure 3-75. Check forproper side clearance with thickness gauge, as shown.

NOTEIf the ring grooves are clean and the side play is still not cor-rect, replace the rings, the piston or both.

Figure 3-73. Installing Piston Rings

Figure 3-74. Ring End Gap Position

Figure 3-75. Measuring Ring Clearance in Groove

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Transmission Shaft Retaining Ring Pliers (Part No. J-5586)

Position ring end gaps at arrows–minimum of 90° apart

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Piston pin

REAR

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Connecting Rod BushingREMOVAL/INSTALLATION

When connecting rod bushing is worn to excessive pin clear-ance (0.002 in. or more) (0.051 mm) it must be replaced.

1. Secure connecting rod with CONNECTING RODCLAMPING TOOL (Part No. HD-95952-33B).

2. See Figure 3-77. Attach PISTON PIN BUSHING TOOL(Part No. HD-95970-32D) to the connecting rod. Thereceiver cup fits on one side of the rod while the driverfits on the opposite side as shown.

3. Use two box wrenches and push worn bushing from con-necting rod.

4. Remove piston pin bushing tool from connecting rod.

5. Remove bushing from receiver cup.

6. Place new bushing between connecting rod and driver.

NOTEThe driver must be attached facing the opposite direction as itwas for removal of the bushing.

7. Clean up and size bushing to 0.0010-0.0005 in.(0.0254-0.0127 mm) undersize using REAMER (PartNo. HD-94800-26A). Sizing bushing with less than0.00125 in. (0.03175 mm) clearance can result in abushing loosening and/or seized pin in rod.

8. Hone bushing to final size using WRIST PIN BUSHINGHONE (Part No. HD-35102). Use a liberal amount ofhoning oil to prevent damage to hone or bushing. Usecare to prevent foreign material from falling into thecrankcase.

CAUTION

Replace bent connecting rods. Do not attempt tostraighten. Straightening rods by bending will damagethe bearing on the crank pin and the piston pin bushing.Installing bent connecting rods will damage cylinder andpiston beyond repair.

Figure 3-76. Installing New Piston Pin Bushing

Figure 3-77. Piston Pin Bushing Tool Assembly for Bushing Removal

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1. Piston Pin Bushing Tool (Part No. HD-95970-32D)

2. Rod Clamping Tool (Part No. HD-95952-33B)

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ASSEMBLY/INSTALLATION

1. See Figure 3-78. Place PISTON SUPPORT PLATE (PartNo. HD-42322) in position as shown.

2. Install piston assembly over connecting rod.

NOTEPiston must be installed with the arrow, at the top of the pis-ton, pointing towards the front of the engine.

3. Install piston pin.

CAUTION

Always use new retaining ring. Make sure retaining ringgroove is clean and that ring seats firmly in groove. If itdoes not, discard the ring. Never install a used retainingring or a new one if it has been installed and thenremoved for any reason. A loosely installed ring willcome out of the piston groove and damage cylinder andpiston beyond repair.

4. See Figure 3-79. Install new piston pin retaining rings (1)using PISTON PIN RETAINING RING INSTALLER (2)(Part No. HD-34623B). Place new retaining ring on toolwith gap pointing up. See Figure 3-80.

NOTEMake sure the ring groove is clean. Ring must be fully seatedin the groove with the gap away from the slot at the bottom.

5. See Figure 3-74. Make sure the piston ring end gaps areproperly positioned as shown.

6. See Figure 3-81. Turn engine until piston is resting ontop of PISTON SUPPORT PLATE (Part No. HD-42322)top dead center.

Figure 3-78. Piston Support Plate

Figure 3-79. Installing Piston Retaining Rings

Figure 3-80. Installing Retaining Ring

Piston Support Plate

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1. Piston Pin Retaining Ring2. Piston Pin Retaining Ring Installer (Part No. HD-

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7. Lubricate cylinder wall, piston, pin and rod bushing withengine oil.

8. See Figure 3-82. Compress the piston rings using PIS-TON RING COMPRESSOR (Part No. HD-96333-51C).

9. Remove protective sleeves from cylinder studs. Install anew cylinder base gasket. Make sure the piston does notbump the studs or crankcase.

10. Install cylinder over piston.

11. Remove PISTON RING COMPRESSOR.

12. Assemble cylinder head. See 3.5 CYLINDER HEAD.

13. Install cylinder head. See 3.5 CYLINDER HEAD.

14. Install assembled engine. See 3.4 ENGINE INSTALLA-TION.

Figure 3-81. Piston Support Plate

Figure 3-82. Compressing Piston Rings

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1. Piston Support Plate (Part No. HD-42322)

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1. Piston Ring Compressor (Part No. HD-96333-51C)


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